U.S. patent number 8,499,858 [Application Number 13/412,918] was granted by the patent office on 2013-08-06 for modular top drive lubrication system and methods.
This patent grant is currently assigned to Canrig Drilling Technology Ltd.. The grantee listed for this patent is Greg Kostiuk, Beat Kuttel, Randall S. Pyrch, Alan S. Richardson, Faisal J. Yousef. Invention is credited to Greg Kostiuk, Beat Kuttel, Randall S. Pyrch, Alan S. Richardson, Faisal J. Yousef.
United States Patent |
8,499,858 |
Kuttel , et al. |
August 6, 2013 |
Modular top drive lubrication system and methods
Abstract
A top drive system with a plurality of top drive modules, which
are configured to be quickly exchanged. The top drive modules may
include any or all of the following: a main body module, a gearbox
module, a drive motor module, a pipe handler module, an upper fluid
module, a lower well control valve module, a block interface
module, a retract system interface frame module, a cooling system
module, a work platform guard module, and a quill saver sub module.
Alternatively, the top drive may comprise a first top drive and a
second top drive which are configured to be quickly exchanged.
Inventors: |
Kuttel; Beat (Spring, TX),
Pyrch; Randall S. (Montgomery, TX), Yousef; Faisal J.
(Houston, TX), Richardson; Alan S. (The Woodlands, TX),
Kostiuk; Greg (Houston, TX) |
Applicant: |
Name |
City |
State |
Country |
Type |
Kuttel; Beat
Pyrch; Randall S.
Yousef; Faisal J.
Richardson; Alan S.
Kostiuk; Greg |
Spring
Montgomery
Houston
The Woodlands
Houston |
TX
TX
TX
TX
TX |
US
US
US
US
US |
|
|
Assignee: |
Canrig Drilling Technology Ltd.
(Houston, TX)
|
Family
ID: |
38218815 |
Appl.
No.: |
13/412,918 |
Filed: |
March 6, 2012 |
Prior Publication Data
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Document
Identifier |
Publication Date |
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US 20120160570 A1 |
Jun 28, 2012 |
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Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
Issue Date |
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12903764 |
Oct 13, 2010 |
8151909 |
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11613685 |
Dec 20, 2006 |
7828085 |
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60752116 |
Dec 20, 2005 |
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Current U.S.
Class: |
175/162;
166/77.51; 175/203 |
Current CPC
Class: |
E21B
19/16 (20130101); E21B 19/00 (20130101); E21B
3/02 (20130101); Y10T 29/4973 (20150115); Y10T
408/675 (20150115); Y10T 29/49723 (20150115) |
Current International
Class: |
E21B
3/00 (20060101) |
Field of
Search: |
;166/77.51
;175/162,203,87 |
References Cited
[Referenced By]
U.S. Patent Documents
Other References
ISA/US, International Search Report and Written Opinion of the
International Searching Authority, PCT/US2006/62414, mailed Oct.
15, 2007. cited by applicant .
WIPO, International Preliminary Report on Patentability,
PCT/US2006/62414, issued Jun. 24, 2008. cited by applicant .
European Patent Office, European Search Report dated Feb. 27, 2012,
Application No. 06846724.0-1266/1984137 PCT/ US2006062414, 7 pages.
cited by applicant.
|
Primary Examiner: Wright; Giovanna
Attorney, Agent or Firm: Haynes and Boone, LLP
Parent Case Text
CROSS-REFERENCE TO RELATED APPLICATIONS
This application is a continuation of U.S. patent application Ser.
No. 12/903,764 filed Oct. 13, 2010, now U.S. Pat. No. 8,151,909,
issued Apr. 10, 2012, which is a continuation of U.S. application
Ser. No. 11/613,685 filed Dec. 20, 2006, now U.S. Pat. No.
7,828,085, issued Nov. 9, 2010, which claims the benefit of U.S.
Application No. 60/752,116, filed Dec. 20, 2005, the contents of
each of which are hereby incorporated herein by express reference
thereto.
Claims
What is claimed is:
1. An apparatus, comprising: a drilling rig; a drill string
extending within a borehole in a subterranean formation; and a top
drive apparatus comprising a spindle and a top drive housing,
wherein the top drive is suspended from the drilling rig via an
interface to the a top drive housing, wherein the drill string is
suspended from the top drive apparatus via an interface to the
spindle, and wherein the top drive apparatus further comprises: a
bearing coupled between the spindle and top drive housing; a
gearbox coupled between the spindle and top drive housing; a
bearing lubrication system fluidly coupled to the bearing and not
the gearbox; and a gearbox lubrication system fluidly coupled to
the gearbox and not the bearing, wherein: the gearbox lubrication
system is to operate in the presence of forced lubricant
circulation; the bearing lubrication system is to operate in the
absence of forced lubricant circulation; the gearbox lubrication
system is to operate in the presence of lubricant filtration; the
bearing lubrication system is to operate in the absence of
lubricant filtration; the bearing lubrication system comprises a
sump, a reservoir, and a riser coupled to the sump and the
reservoir; and the riser is fluidly coupled to the bearing.
2. The apparatus of claim 1 wherein at least one of the bearing and
the gearbox is directly coupled between the spindle and top drive
housing.
3. The apparatus of claim 1 wherein at least one of the bearing and
the gearbox is indirectly directly coupled between the spindle and
top drive housing.
4. The apparatus of claim 1 wherein the bearing is directly coupled
between the spindle and top drive housing, and wherein the gearbox
is indirectly coupled between the spindle and top drive
housing.
5. An apparatus, comprising: a top drive apparatus comprising: a
spindle; a top drive housing; a bearing coupled between the spindle
and top drive housing; a gearbox coupled between the spindle and
top drive housing; a bearing lubrication system fluidly coupled to
the bearing and not the gearbox; and a gearbox lubrication system
fluidly coupled to the gearbox and not the bearing, wherein: the
gearbox lubrication system is to operate in the presence of forced
lubricant circulation; the bearing lubrication system is to operate
in the absence of forced lubricant circulation; the gearbox
lubrication system is to operate in the presence of lubricant
filtration; the bearing lubrication system is to operate in the
absence of lubricant filtration; the bearing lubrication system
comprises a sump, a reservoir, and a riser coupled to the sump and
the reservoir; and the riser is fluidly coupled to the bearing.
6. The apparatus of claim 5 wherein the apparatus further comprises
a drill string extending within a borehole in a subterranean
formation, and wherein the spindle is coupled to the drill
string.
7. The apparatus of claim 5 wherein at least one of the bearing and
the gearbox is directly coupled between the spindle and top drive
housing.
8. The apparatus of claim 5 wherein at least one of the bearing and
the gearbox is indirectly directly coupled between the spindle and
top drive housing.
9. The apparatus of claim 5 wherein the bearing is directly coupled
between the spindle and top drive housing, and wherein the gearbox
is indirectly coupled between the spindle and top drive
housing.
10. An apparatus, comprising: a top drive apparatus comprising: a
spindle; a top drive housing; a bearing coupled between the spindle
and top drive housing; a gearbox coupled between the spindle and
top drive housing; a bearing lubrication system fluidly coupled to
the bearing and not the gearbox; and a gearbox lubrication system
fluidly coupled to the gearbox and not the bearing.
11. The apparatus of claim 10 wherein the bearing is directly
coupled between the spindle and top drive housing, and wherein the
gearbox is indirectly or directly coupled between the spindle and
top drive housing.
12. The apparatus of claim 11 wherein a first one of the gearbox
lubrication system and the bearing lubrication system is to operate
in the presence of forced lubricant circulation, and wherein a
second one of the gearbox lubrication system and the bearing
lubrication system is to operate in the absence of forced lubricant
circulation.
13. The apparatus of claim 11 wherein the gearbox lubrication
system is to operate in the presence of forced lubricant
circulation, and wherein the bearing lubrication system is to
operate in the absence of forced lubricant circulation.
14. The apparatus of claim 11 wherein a first one of the gearbox
lubrication system and the bearing lubrication system is to operate
in the presence of lubricant filtration, and wherein a second one
of the gearbox lubrication system and the bearing lubrication
system is to operate in the absence of lubricant filtration.
15. The apparatus of claim 11 wherein the gearbox lubrication
system is to operate in the presence of lubricant filtration, and
wherein the bearing lubrication system is to operate in the absence
of lubricant filtration.
16. The apparatus of claim 11 wherein a first one of the gearbox
lubrication system and the bearing lubrication system is to operate
in the presence of both lubricant filtration and forced lubricant
circulation, and wherein a second one of the gearbox lubrication
system and the bearing lubrication system is to operate in the
absence of both lubricant filtration and forced lubricant
circulation.
17. The apparatus of claim 11 wherein the gearbox lubrication
system is to operate in the presence of both lubricant filtration
and forced lubricant circulation, and wherein the bearing
lubrication system is to operate in the absence of both lubricant
filtration and forced lubricant circulation.
18. The apparatus of claim 11 wherein the bearing lubrication
system comprises a sump, a reservoir, and a riser coupled to the
sump and the reservoir.
19. The apparatus of claim 11 wherein the bearing lubrication
system comprises a sump, a reservoir, and a riser coupled to the
sump and the reservoir, wherein the riser is fluidly coupled to the
bearing.
20. The apparatus of claim 11 wherein the top drive apparatus is to
drive a drill string extending within a borehole in a subterranean
formation.
Description
BACKGROUND OF THE INVENTION
Increasingly, drilling contractors are using top drives instead of
Kellies or Kelly bushings. A top drive is a drilling tool that
hangs from the traveling block, and has one or more motors to power
a drive shaft to which crewmembers attach the drill string. Because
the top drive's motor can rotate the drill string, no Kelly or
Kelly bushing is required. The top drive also incorporates a
spinning capability and a torque wrench. In addition the top drive
has elevators on links. The benefits of top drives may include the
ability to work in 90 feet increments rather than the 30 feet
increments to which a Kelly is typically limited. That is, a joint
of tubular is typically 30 feet long. Thus, a top drive allows an
operator to work with 3 joints of tubular per increment of a given
operation. For example, top drives allow operators to assemble
three-joint (90 feet) stands of tubular off the critical path to
save time. Similarly, in some instances, such as, for example,
applications involving horizontal or highly deviated well bores, it
may be desirable to remove tubular from a well bore by a process
known as back reaming. A top drive allows operators to back ream
tubular from a well bore in three-joint stands of tubular, which
may then be racked intact.
On a drilling rig, the critical path includes all tasks and
equipment required to continue drilling without interruption. When
a task or equipment on the critical path is delayed, the entire
drilling operation is delayed. Thus, because mechanical devices
require some amount of repair and/or maintenance, many drilling rig
critical path components are maintained in redundant quantities to
decrease downtime caused by inevitable repair and maintenance.
Conventionally, top drives have been an exception to this principle
of redundancy. Because top drives are generally on the critical
path, top drives create the potential for single point
failure--that is, if the top drive goes down, the entire drilling
operation stalls, rendering the entire rig nonoperational until the
top drive can be brought back online. Generally, diagnostics occur
in the critical path before any repairs can be done, causing
additional delay in the operation before repair even begins.
Likewise, maintenance operations can fall within the critical path,
creating downtime.
SUMMARY OF THE INVENTION
The present invention relates to the field of oil or gas well
drilling and more particularly to a method and apparatus for
drilling a well and handling tubulars.
According to one aspect of the invention, there is provided a top
drive system comprising: a first top drive; and a second top drive,
wherein the first and second top drives are configured to be
quickly exchanged.
A further aspect of the invention provides a top drive system
comprising: a plurality of modules; wherein the modules are
configured to be quickly exchanged.
Yet another aspect of the invention provides a method of increasing
drilling efficiency comprising: providing a first top drive module
on a critical path; providing a second top drive module off the
critical path; replacing the first top drive module with the second
top drive module such that the second top drive module is on the
critical path and the first top drive module is off the critical
path.
The invention further encompasses a top drive system including a
top drive, a gearbox module fluidly coupled to a gearbox
lubrication system of the top drive system, and at least one
bearing adapted for lubrication by a bearing lubrication system
fluidly coupled to the at least one bearing, wherein the bearing
lubrication system is separate from at least the gearbox
lubrication system so as to prevent any wear debris in the gearbox
and gearbox lubrication system from interacting with the at least
one bearing and the bearing lubrication system. In one embodiment,
the bearing lubrication system is adapted to convectively circulate
lubricant. In another embodiment, the bearing lubrication system
convectively circulates lubricant in the absence of forced
circulation. In a preferred embodiment, the bearing lubrication
system is adapted to naturally convectively circulate
lubricant.
In one embodiment, the gearbox lubrication system includes a
filter. In another embodiment, the gearbox lubrication system is
adapted to circulate via a pumping system. In yet another
embodiment, the gearbox module is adapted to be quickly replaced
with a replacement gearbox module that is off a critical path. In a
preferred embodiment, the gearbox module is configured to connect
to the top drive through a splined connection and one or more
fasteners. In yet another embodiment, the gearbox module includes
one or more of the following: a one-speed gearbox; a multi-speed
gearbox; one or more input shafts for each of one or more coupled
drive motors; one or more torque keys or quick latch assemblies to
facilitate rapid removal and installation; and a splined bull gear
to transmit torque to the spindle. In a preferred embodiment, the
one-speed gearbox has a reduction ratio range from about 6.89:1 to
9:1. In yet a further embodiment, the gearbox lubrication system
includes at least one of the following: a dry sump reservoir; a
suction strainer; one or more screw pumps and one or more electric
motors; one or more filters; a distribution manifold; a sensor for
sensing oil pressure; and a lube oil cooler.
The invention further encompasses a top drive system, including: a
top drive including at least one bearing, and a bearing lubrication
system fluidly coupled to the at least one bearing, wherein the
bearing lubrication system is adapted to lubricate the at least one
bearing through convective circulation and gravity in the absence
of forced circulation. In another embodiment, the bearing
lubrication system is further adapted to circulate unfiltered
lubrication. In yet a further embodiment, the bearing lubrication
system is fluidly isolated from any other lubrication system
associated with the top drive.
The invention additionally encompasses methods for minimizing
bearing replacement in a top drive by convectively circulating
filtered lubricant in at least a gearbox module of the top drive to
provide lubrication thereto, and separately convectively
circulating a second lubricant in association with at least one
bearing in the top drive, whereby the filtered lubricant and the
second lubricant are isolated to minimize contact between wear
debris from any module including at least the gearbox module and
the at least one bearing. In one embodiment, the second lubricant
is the same as the first lubricant. In a preferred embodiment, the
second lubricant is naturally convectively circulated.
Further, the invention encompasses a top drive system including a
top drive, and a retract system interface frame module which
includes a connection configuration adapted to mate with a variety
of retract systems so as to make the retract system interface frame
module quickly interchangeable with an off critical path
replacement retract system interface frame module. In one
embodiment, the retract system interface frame module includes at
least one of an auto lubrication system, a junction box, a cooling
system module, blowers for motor cooling, a programmable logic
control, or a lubrication filtration system. In another embodiment,
the retract system interface frame module is configured to move
away from a second module of the top drive to facilitate rapid
access to the second module. In yet a further embodiment, the
retract system interface frame module rotates away from the second
module. In still another embodiment, the retract system interface
frame module includes a connection configuration in association
with a plurality of guides to facilitate rapid interchange of a
pair of one or more alternate top drive modules associated with the
top drive.
It should be understood that each of the embodiments herein may be
used alternatively or additively, as may be appropriate.
BRIEF DESCRIPTION OF THE DRAWINGS
The present invention may be better understood by reading the
following description of non-limitative embodiments with reference
to the attached drawings wherein like parts of each of the several
figures are identified by the same referenced characters, and which
are briefly described as follows:
FIG. 1 is a perspective view of an embodiment of the top drive
system having the following top drive modules: a main body, a
gearbox, two drive motor modules, a pipe handler, an upper fluid
module, a lower well control valve, a block interface, two work
platform guard modules, two cooling system modules, a quill saver
sub module, and a retract system interface frame module.
FIG. 2 is an exploded view of an embodiment of the top drive system
of FIG. 1.
FIG. 3 is a partially cut away perspective view of one embodiment
of a bearing lubrication system.
FIG. 4 is a partially cut away perspective view of one embodiment
of a gearbox lubrication system.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
The present invention relates to the field of oil or gas well
drilling and more particularly to a method and apparatus for
drilling a well and handling tubulars. Referring now to FIG. 1,
according to one embodiment of the invention, a top drive system
1000 is provided having a number of top drive modules. Referring
now to FIG. 2, in a particular embodiment, the top drive modules
may include one or any number of the following: a main body module
1100, a gearbox module 1200, two drive motor modules 1300, a pipe
handler module 1400, an upper fluid module 1500, a lower well
control valve module 1600, a block interface module 1700, two work
platform guard modules 1800, two cooling system modules 1900, a
quill saver sub module 2000, and a retract system interface frame
module 2100. Each of these modules may have components and features
as listed below.
When it becomes necessary to perform maintenance on a particular
component of a modular top drive system of the present invention,
for example top drive system 1000, due to failure or routine
maintenance, a top drive module containing that component may be
quickly replaced with a corresponding top drive module that is
already in proper working order. This allows operations to continue
without significant interruption. As operations continue,
maintenance and/or repairs can be performed on the component off
the critical path, such that the top drive module that was removed
can be used when the need arises. Alternatively, the entire top
drive module may be sent off site for repair or the top drive
module may be disposed of.
A further aspect of a modular top drive of the present invention is
the ability for dual activities to occur simultaneously. By way of
example, and not of limitation, the replacement of a drive motor on
a conventional top drive is a lengthy process due to the serial
nature of the replacement steps. That is, the electrician may need
to disconnect the drive motors electrical connections before the
mechanic may remove the drive motor. Then the mechanic may align
and install the replacement drive motor. Then the electrician may
make the electric connections to the new drive motor. Conversely, a
modular top drive of the present invention may be assembled such
that the electrical connections are physically located far enough
away from the mechanical connections such that the electrician and
the mechanic may perform their tasks in parallel, that is, at the
same time or nearly the same time, hence reducing downtime.
Interchangeable top drive modules may also be desirable for reasons
beyond maintenance or repair. For instance, different top drive
modules may be used for different drilling and/or make-up
configurations. In certain drilling applications, different drill
speeds may be required. Rather than using a variable or multi-speed
gearbox, the different speeds may be provided by exchanging gearbox
modules with different single speed gear arrangements that are
simpler and more reliable. Similarly, different tubular diameters
may be accommodated by exchanging lower well control valve modules.
Similarly, different drive motor modules may be better suited to
different applications such as coring, drilling, and workover.
Other advantages of different modular configurations will be
apparent, with the benefit of this disclosure, to a person of
ordinary skill in the art.
Depending on the specific top drive system 1000 and the specific
conditions, there may be any number of top drive modules. For
example, a single top drive module may be used. In this example,
the top drive module may include the entire top drive system 1000,
and be interchangeable with another complete top drive system
module 1000. This configuration requires no diagnostics to
determine which component is problematic until the top drive system
1000 is off-line. Similarly, a short module replacement time
simplifies the repair or replace decision-making process such that
a module may be quickly replaced and diagnostics conducted on the
replaced module off the critical path. If replacing the entire top
drive system 1000 is not practical, or is otherwise not desired,
multiple top drive modules may be used. The components of the top
drive system 1000 may be grouped into modules in any number of
ways, and the configuration of the individual modules should not be
limited by the specific embodiment(s) discussed below.
The top drive modules of a modular top drive system of the present
invention may be coupled according to a variety of techniques, so
long as the techniques allow for quick change capability of the
modules of a modular top drive. Additionally, it is desirable that
the connections readily allow for the exchange of one top drive
module for a similar top drive module. Furthermore, it may be
desirable for the connection mechanisms to allow for vertically
lifting and lowering of the top drive modules as they are connected
and disconnected to a modular top drive system. Suitable connection
techniques include, but are not limited to, a multi-unit retract
system, bolts, inserts and pins, dovetail slide-ons, eccentric jam
devices, keyway slots, pilot rings and clamps, splined connections,
split rings, guide pins, torque arrest mechanisms, O-ring seals,
flanges, pins and slots, and any combination thereof. Additionally,
a person of ordinary skill in the art will be aware, with the
benefit of this disclosure, of other techniques for coupling the
modules of a modular top drive system.
In one exemplary embodiment, shown in FIG. 2, a top drive system
100 may have a main body module 1100, a gearbox module 1200, two
drive motor modules 1300, a pipe handler module 1400, an upper
fluid module 1500, a lower well control valve module 1600, a block
interface module 1700, two work platform guard modules 1800, two
cooling system modules 1900, a quill saver sub 2000, and a retract
system interface frame module 2100.
The main body module 1100 may serve as a base, and other top drive
modules or components may be attached to the main body module 1100,
either directly or indirectly, using one or more of the connection
techniques described above. The main body module 1100 may have any
or all of the following: a top drive housing 1110 (FIG. 3) with
mounts for a block interface module 1700; main bearings; a hollow
spindle 1120 (FIG. 3), which may be splined for connection to
gearbox module 1200; a floating quill 1130 (FIG. 3), which may have
8 inch free float travel and a male spline connection; an upper
bearing carrier with motor mounts; a retract system interface frame
with blowers for motor cooling; and an auto grease system. Some
embodiments may have a self contained splash lubrication system
that is itself modular. Similarly, some embodiments, for example
top drive system 1000, may have a retract system interface frame
that is itself modular. The main body module 1100 may additionally
or alternatively include any other components that would typically
remain intact when changing out other top drive modules.
The gearbox module 1200 may be quickly attached to, or detached
from, the main body module 1100 using one or more of the connection
techniques described above. For example, the connection may be via
a spline and pins that act as a gravity retention as well as a
torque arresting mechanism. This allows the gearbox module 1200 to
be completely removed and replaced with another gearbox module
1200, allowing for repair of any components therein off the
critical path. The gearbox module 1200 may have any or all of the
following: a simple one speed gearbox, which may have a reduction
ratio between about 6.890 to 1 and 9.000 to 1; input shafts for one
or more coupled drive motors; one or more couplings with guard and
drive shaft; inspection view windows; one or more torque keys and
quick latch assemblies for easy removal and installation; a splined
bull gear to transmit torque to the spindle; and a self-contained
gearbox lubrication system. The self-contained gearbox lubrication
system may include the following: a dry sump reservoir; a suction
strainer; one or more screw pumps and one or more electric motors;
one or more filters with visual indicators and remote sensors; a
distribution manifold; a remote sensor for sensing oil pressure;
and a lube oil cooler with an electric fan. In some embodiments,
the gearbox module 1200 may include a multi speed gearbox. In other
embodiments, a plurality of single speed gearboxes, which may be
quickly interchangeable, may be more preferable than one or more
multi-speed gearboxes for reasons of reliability. The gearbox
module 1200 may additionally or alternatively include any other
components that would typically be associated with the components
of the gear system.
The drive motor module 1300 may be quickly attached to, or detached
from the main body module 1100 using one or more of the connection
techniques described above. This allows the drive motor module 1300
to be completely removed and replaced with another drive motor
module 1300. This allows for the repair of components of the drive
motor module 1300 to take place off the critical path. The drive
motor module 1300 may include one or more motors, such as AC
electric motors, GE model GEB-20, 1150 HP; a motor module frame to
allow quick installation and removal of the entire drive motor
module 1300; a coupling to the gearbox module 1200 for quick
alignment or isolation in the event of a failure; a brake system; a
programmable logic controller ("PLC") junction box or simple
electrical junction box for control and sensors; and a guard and
lifting assembly. The brake system may include the following: five
(5) disk brake calipers; hydraulic controls; and an auto bleed
system. In some embodiments, it may be desirable to locate the
electrical connections of drive motor module separate from the
mechanical connections, so as to enable dual activities during
replacement, maintenance, and/or repair. The drive motor module
1300 may additionally or alternatively include any other components
that would typically be associated with the components of the motor
system.
The pipe handler module 1400 may be quickly attached to, or
detached from the main body module 1100 using one or more of the
connection techniques described above. For example, the connection
may be made via a slide-on module using split rings as the main
connection method, along with guide pins which act as a locating
guide and as a torque arrest method. This allows the pipe handler
module 1400 to be completely removed and replaced with another pipe
handler module 1400. This allows for the repair of components to
take place off the critical path. The pipe handler module 1400 may
include any or all of the following: a mounting plate; a rotary
manifold for hydraulic and air communication; an elevator link
support; an integrated link counter balance system; a link tilt
assembly; a back-up wrench; a handling frame for ease of movement
when removed; and an auto grease system. The mounting plate may
include the following: hydraulic valve banks direct mounted to a
porting plate to eliminate hoses and leak points; a redundant
handler to rotate modules; a redundant handler to lock modules;
dual PLC junction boxes with quick connects; and a fold down guard,
which may double as a work platform. Some embodiments, for example
top drive system 1000, may have one or more fold down guards that
are themselves modular, for example, work platform guards 1800. The
rotary manifold may include the following: twenty (20) passages
with test ports and radial bearings for centralization. The link
tilt assembly may have bi-directional hydraulic actuation and float
capabilities. The back-up wrench may have quick change capability
with driller controlled vertical positioning and include the
following: a hydraulic gripper, with a capacity up to 11 inch
diameter and 120,000 ft/lb torque; driller controlled vertical
positioning; removable die blocks; and a pipe stabbing guide. The
pipe handler module 1400 may additionally or alternatively include
any other components that would typically be associated with the
components of the pipe handling system.
The upper fluid module 1500 may be quickly attached to, or detached
from the main body module 1100 using one or more of the connection
techniques described above. For example, the bonnet may be bolted
or pinned to the main body module via a spline and an O-ring seal
connection. Alternatively, a clamp or flange and O-ring seal may be
used. This allows the upper fluid module 1500 to be completely
removed and replaced with another upper fluid module 1500. This
allows for the repair of components to take place off the critical
path. The upper fluid module 1500 may include a washpipe assembly
with 7500 PSI WP, 4 inch bore; an upper sealing including a wiper,
a flinger, a labyrinth seal, and lubrication oil seals for mud
exclusion; and a mud line with top access 7500 PSI WP, 4 inch bore.
The upper fluid module 1500 may additionally or alternatively
include any other components that would typically be associated
with the components of the fluid system.
The lower well control valve module 1600 may be quickly attached
to, or detached from the main body module 1100 using one or more of
the connection techniques described above. For example the
connection may be made via the split ring connection of a quill
saver sub module 2000. This allows the lower well control valve
module 1600 to be completely removed and replaced with another
lower well control valve module 1600. This allows for the repair of
components to take place off the critical path. The lower well
control valve module 1600 may include a splined quill saver sub,
for example, quill saver sub module 2000, which may be splined for
quick removal, allowing multiple quill connections to match a given
drill string. Additionally, a splined quill saver sub, for example,
quill saver sub module 2000, may accommodate future and unforeseen
drill string connections. The saver sub may have a remote operated
lower well control valve; a hydraulic valve actuator; two manual
lower well control valves; and connection clamps. Examples and
properties of quill saver subs are further disclosed in U.S.
application Ser. No. 11/405,940, which is hereby incorporated by
reference. The lower well control valve module 1600 may
additionally or alternatively include any other components that
would typically be associated with the components of the lower well
control system.
The block interface module 1700 may be quickly attached to, or
detached from the main body module 1100 using one or more of the
connection techniques described above. For example, the connection
may be made using a pin and slot connection or a split-ring
connection. This allows for the repair or inspection of load path
components to take place off the critical path. The block interface
module 1700 may include four upper links; two link to bail
adapters; a block adapter; and four load cell pins. The block
interface module 1700 may additionally or alternatively include any
other components that would typically be associated with the
components of the block system. The block interface module 1700 may
be exchanged for another block interface module, for example, when
changing rigs.
The cooling system module 1900 may be quickly attached to, or
detached from, one or more of the main body module 1100, the drive
motor module 1300, and the retract system interface frame module
2100 using one or more of the connection techniques described
above. This allows the cooling system module 1900 to be completely
removed and replaced with another cooling system module 1900. This
allows for the repair of components to take place off the critical
path. In some embodiments, cooling system module 1900 may be hinged
or other wise connected to a part of a modular top drive system,
for example retract system interface frame module 2100, such that
cooling system module 1900 may be rotated away from, for example,
drive motor module 1300 to provide enhanced access to the same. The
cooling system module 1900 may have one or more circulators, for
example a blower and/or a pump, and one or more ducts. In some
embodiments, the one or more circulators and the one or more ducts
may themselves be modular. The cooling system module 1900 typically
uses air to cool. However, any coolant may be used. The cooling
system module 1900 may additionally or alternatively include any
other components that would typically be associated with the
component of the cooling system.
The retract system interface frame module 2100 may be particularly
useful when interchanging an entire top drive system 1000. The
retract system interface frame module 2100 may have a pin
configuration that may interface to a plurality of guide dollies
and/or retract systems, such that the retract interface frame
module 2100 is interchangeable between derricks. The retract system
interface frame module 2100 may contain an auto lube system. The
retract system interface frame module 2100 may additionally or
alternatively include other components, for example, junction
boxes, cooling loops, PLCs, lube systems, filters for lube systems,
and the like, to allow for dual activities when replacing the
modules of a modular top drive system of the present invention. The
retract system interface frame module 2100 may additionally or
alternatively include any other components that would typically be
associated with the components of the retract system interface
frame system.
According to other embodiments of the invention, a modular top
drive system of the present invention may be an interchangeable top
drive system comprising dual top drive systems such as, for
example, top drive system 1000. This enables the operators to
trouble-shoot and/or configure the off-line top drive while the
other top drive is in operation. The operators may change out a
complete top drive. Each of the top drives may have permanently
installed service loops. Each top drive may be preconfigured for
different drilling and/or make-up configurations.
Another embodiment of the invention relates to different
configurations of a modular top drive system. For example, in
addition to the example embodiment top drive system 1000, another
embodiment may be formed from the following top drive modules: dual
coupled main drive motors, quick change IBOP (LWCV), pipe handler
module 1400, gearbox module 1200, a lube system, and a back-up
wrench. Furthermore, using the principles of modular construction
of a top drive system discussed herein, a person of ordinary skill
in the art will be aware of numerous additional modular
constructions of top drive systems, comprising virtually any number
of top drive modules, which may be suited to numerous drilling,
casing, and any other tubular handling applications.
Some embodiments of the top drive system 1000 have a motor cooling
system. In some embodiments, the cooling system may have modular
components, for example, cooling system module 1900. The system may
be a cooling system for the one or more main drive motors. It may
also have ducts integrated with the top drive support structure,
which may include modular or nonmodular frame and/or guard
structures, such that the ducts are the interiors of hollow beams
of the support structure. One or more circulators may be connected
to the one or more motors through a manifold and/or duct system so
that any of the one or more circulators may cool any and/or all of
the one or more motors. The cooling system may circulate air, or
any other coolant. This builds redundancy into the system.
Embodiments such as, for example, top drive system 1000 may also
have separate lubrication systems for the gearbox and the bearings.
This prevents any wear debris from the gearbox from interacting
with, and potentially damaging, the bearings. In the bearing
lubrication system, there may be no forced circulation and
filtration, and circulation may be achieved through natural
convection and gravity. FIG. 3 shows an example embodiment of such
a bearing lubrication system 2200. The bearing lubrication system
2200 may include a sump 2210 connected to a riser 2220, which
connects to reservoir 2230. Lubricant flows between the riser 2220
and bearings 2240. The bearings 2240 in this example include an
upper race 2241, a roller 2242, and a lower race 2243.
In the gearbox lubrication system, the wear components from the
gear that contaminate the lubricant generally require forced
circulation and filtration. FIG. 4 shows an example embodiment of
such a gearbox lubrication system 2300. The gearbox lubrication
system 2300 may have an oil sump 2310, an oil passage 2320, one or
more circulators (not shown) and one or more filters 2350, which
serve to lubricate a contact surface between an input pinion 2330
and a bull gear 2340. Where a plurality of circulators and/or
filters are used, they may be configured to create redundancy in
the system.
In embodiments with an interchangeable washpipe, the washpipe may
be changed very quickly so that the downtime is minimized. The
change may be done remotely with automatic quick change
capability.
The interchangeability of the various top drive modules may allow
for repairs, maintenance, inspection, and/or operational
reconfiguration to be performed off the critical path. This may
reduce downtime for a modular top drive system, which corresponds
to a reduced downtime for the entire rig. Some or all of the top
drive modules may be symmetrical, allowing for installation in more
than one location on the top drive.
Therefore, the present invention is well adapted to attain the ends
and advantages mentioned as well as those that are inherent
therein. The particular embodiments disclosed above are
illustrative only, as the present invention may be modified and
practiced in different but equivalent manners apparent to those
skilled in the art having the benefit of the teachings herein. For
example, the present invention may be used to run drill pipe, as
well as casing, or other tubulars. Furthermore, no limitations are
intended to the details of construction or design herein shown,
other than as described in the claims below. It is therefore
evident that the particular illustrative embodiments disclosed
above may be altered or modified and all such variations are
considered within the scope and spirit of the present invention.
Also, the terms in the claims have their plain, ordinary meaning
unless otherwise explicitly and clearly defined by the
patentee.
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